Insulated curtain wall construction



p 6, 1969 R. e. GALLAGHER ET AL 3,466,826

INSULATED CURTAIN WALL CONSTRUCTION Filed Sept. 28, 1967 3 Sheets-Sheet 1 L" 2H If 1 I" I E Fl 0. I

INVENTORf .PAYM 0M0 6. GALL Aonsa ,fl-(EWATD J. MA 22am SAMUEL DA UJ'OA/ ATTORNEYS p 1969 R. G. GALLAGHER ET AL 3,466,826

INSULATED CURTAIN WALL CONSTRUCTION Filed Sept. 28. 196'? 1 3 Sheets-Sheet 5 kAYMqNb c-. GALLAGHER Rem-r0 J. M'AZZDNI SAMUEL 0A uson/ FIG. 3 a aqfimk ATTORNEYS United States Patent 3,466,826 INSULATED CURTAIN WALL CONSTRUCTION Raymond G. Gallagher, Pittsburgh, Renato J. Mazzoni, Tarentum, and Samuel Dauson, Gihsonia, Pa., assignors to PPG Industries, Inc., a corporation of Pennsylvania Filed Sept. 28, 1967, Ser. No. 671,270 Int. Cl. E04b 2/88 US. Cl. 52395 5 Claims ABSTRACT OF THE DISCLOSURE An insulated curtain wall construction comprising a panel, a metal panel-backing member adjustably joined by metallic connector means to a metal panel-retaining member, insulating material disposed between said connector means and said backing member so that said panel-backing member and panel-retaining member are insulated from each other and insulating material disposed between said panel and said backing and retaining members so that said panel member is insulated from said backing and retaining members when an edge of said panel member is disposed therebetween.

Background of the invention This invention relates to a wall construction and, in particular, to a novel, insulated curtain wall construction.

In US. Patent No. 3,336,707, assigned to the assignee of the present invention, there is disclosed an insulated curtain wall construction for mounting panels on a frame or grid structure comprising a T-shaped elastomeric structural glazing gasket having the body or arm portion of the gasket in supporting engagement with a panel, the leg portion of the gasket received in an inwardly directed mounting groove in a frame member and gasket engagement means supported within said groove and engaging the leg portion of the gasket to lock the assembly together.

In copending application Ser. No. 596,285, also assigned to the assignee of the present invention, there is disclosed an insulated wall construction for mounting panels comprising horizontal and vertical members interconnected to form a frame and wherein each frame member carries an outwardly directed flange on one common vertical face thereof, an elastomeric structural glazing gasket mounted on said flange to support a panel and insulating panel-backing strips disposed between said panel and said frame member. To the present inventors knowledge, the above constructions represent the only fully insulated curtain Wall systems of their kind.

In known forms of wall construction prior to the above inventions, various attempts were made to provide a thermal grid barrier, i.e., a thermal break in the grid or frame members, as well as a thermal break between the panel members and the grid or frame members, to prevent transfer of heat and cold from one member to another. However, none of these known forms of construction were found to be completely satisfactory.

Even with the advent of the above-mentioned inventions wherein for the first time completely satisfactory constructions were provided for producing both structurally and functionally sound thermal wall system, these systems were nevertheless restricted in appearance and required maintaining close tolerances in the manufacture of their component parts. Each of the foregoing systems required the use of an exposed elastomeric glazing gasket, the appearance of which in a composite wall assembly might not always completely fulfill the aesthetic desires of the architect and/or building owner. Moreover, each of the above-mentioned systems might well be characterized as non-adjustable systems in that they conice tained no provision for positively obtaining a water-tight and/or structurally-tight wall other than by maintaining strict control over field erection and tolerance deviations in the manufacture of their component elements or parts. Thus, the present invention is directed to providing a solution to these latter-mentioned problems and, more specifically, to providing a thermally insulated wall system that is not hampered by tolerance considerations and that may be adapted to provide almost any desired appearance.

The present invention, like those disclosed in the aforementioned patent and copending application, combines all of the best features of known types or forms of curtain wall construction and provides a novel curtain wall system that is structurally sound, that is relatively easy and inexpensive to install, that inherently possesses a complete thermal grid barrier, and that is comparable or lower in cost to any known form of wall construction.

In addition, the curtain wall system of the present invention, unlike those disclosed in the aforementioned patent and copending application, is adjustable to accommodate tolerance deviations and, accordingly, is not inherently or unduly hampered by tolerance considerations. Also, the curtain wall system of this invention permits wide versatility in the finish, color, shape and/or appearance of depth of section of the panel-framing members by reason of employing cap or cover members that can be fabricated to provide practically any desired appearance.

Moreover, the basic curtain wall system of this invention can be completely reversed and thus can accom modate mounting the panels either from the interior or the exterior of the building for maximum freedom in design and installation.

Furthermore, the curtain wall system of the present invention provides a clean or uninterrupted sight line, particularly when viewing directly into the curtain wall. This is important both aesthetically and functionally where the system employs the use of transparent panels.

Novel features of the present invention that make the foregoing advantages possible involve the use of an insulating material that separates and thermally isolates a metal panel-backing member from a metal connector member, which in turn is joined to a spaced, opposed, metal panel-retaining member to which said connector member is threadably or adjustably joined. The metallic panel-backing member and panel-retaining member are each spaced from an interposed panel member by means of insulating glazing material. Furthermore, the panelretaining member is provided with suitable means to attach thereto a wide variety of cover members.

The foregoing and other features and advantages of this invention will be better understood when reference is had to the accompanying drawings, wherein similar parts are usually designated by the same numeral and in which:

FIG. 1 represents an outside elevation of a typical curtain wall constructed in accordance with the present invention;

FIG. 2 is a typical cross-section along the line IIII of FIG. 1 showing the details of vertical framing members constructed in accordance with the present invention; and

FIG. 3 is a typical cross-section along the line IIIIII of FIG. 1 showing the details of horizontal framing mem- 'bers constructed in accordance with the present in- 'vention.

The curtain wall 10, depicted in FIG. 1, consists of a plurality of panels 12, which are separated and supported along their peripheral edges by horizontal and vertical panel-framing members or grid members 14 and 16 of substantially identical cross-section. The frame member shown at 16' in FIG. 2 is a split member. Split members are frequently employed to accommodate expansion in the walls of a building, For the purpose of the present invention, however, the frame member 16' may also be a one-piece extrusion or it may be a sectionalized member of cross-sectional configuration somewhat different than that shown in FIG. 2. In addition, unitary and/or sectionalized frame members can be used in any desired combination. Notwithstanding the above, the essential requirements of the horizontal and vertical members 14 and 16 of the present invention are the same, and thus, for the purpose of the following description, reference may be had to either FIG. 2 or 3 for details that are common and essential to both members.

Although FIG. 1 is intended to show horizontal and vertical framing members supporting a plurality of panels covering a complete wall section, it Will be appreciated from the following description that the present invention in equally well adapted to single or muliple panel constructions. The panels 12 may be of an insulating or noninsulating type and of any suitable material or construction.

Referring to FIG. 1, horizontal framing members 14 and vertical framing members 16 are joined to form a rigid structural frame or framework. With particular reference being had to FIGS. 2 and 3, the horizontal and vertical framing members 14 and 16 are each composed essentially of a metal panel-backing member 18, insulating material 20, a metal connector 22, and a metal panel-retaining member 24 to which connector 22 is adjustably joined. The metallic panel-backing member 18 and panel-retaining member 24 are each spaced from an interposed panel member 12 by means of insulating glazing strips 26. The panel-retaining member 24, in the embodiment shown, is attached to connector member 22 by screw fasteners 28 and, in addition, is provided with a pair of longitudinally extending ribs or flanges 30 over which a cover or cap member 32 is snapped into place.

Referring specifically to FIG. 2 for further details, panelbacking member 18 is an elongated structural member composed of a tubular or channel-shaped stiffening portion 34 that imparts rigidity and strength to the framing member and that carries thereon a panel-backing portion 36 which may be either a separate member joined to the stilfening portion or may be formed integrally with the stiffening portion 34.

In the embodiment shown, panel-backing portion 36 comprises a pair of integral flanges 38 extending from the stiffening portion 34 of the panel-backing member 18 and having a structure formed thereon, such as longitudinally extending flanges 40 that carry longitudinally extending grooves 42, adapted to support insulating glazing strips 26. Between longitudinally extending flanges 38 and 40 and web 35 of stiffening portion 34, there is provided an inwardly directed, longitudinally extending C-shaped groove 44 which receives and retains one or more insulating members 20 and one or more connector members 22. Thus, it is contemplated that the insulating members 20 and/ or connector members 22 may either be continuous members that are essentially coextensive with the length of C-shaped groove 44 or one or both may comprise members of relatively shorter length, e.g., 1 /2 inches to 4 inches, appropriately spaced along the length of C-shaped groove 44 and joined in assembled relation.

C-shaped groove 44, as aforesaid, is formed by longitudinally extending flanges 38 and 40 and web 35 of stiffening portion 34 of the panel-packing member. Flanges 40 provide means for positively resisting disengagement of insulating members 20 from C-shaped groove 44. The opening or access 46 into C-shaped groove 44 provided between flanges 40 provides means for extending connector member 22 forwardly or outwardly from the C- shaped groove 44 of panel-backing member 18. As shown, access opening 46 is larger than the corresponding linear dimension of the proximate portion of stem 48 of connector member 22 so that in the installed position of the connector member 22 there is no physical contact between connector member 22 and panel-backing member 18.

Insulating member 20 is a generally C-shaped member of natural or synthetic rubber or other insulating material that essentially corresponds in outer peripheral shape and size to the peripheral shape and size of C-shape groove 44. C-shaped insulating member 20 has a longitudinally extending C-shaped groove 50 formed therein. In its installed position, the opening 52 into C-shaped groove 50 of insulating member 20 corresponds in location to the opening 46 in C-shaped groove 44 of the panel-backing portion 36 of the panel-backing member for the purpose of receiving connector member 22. C-shaped groove 50 of insulating member 20 essentially corresponds in shape and size to the outer peripheral shape and size of the companion portion 54 of connector member 22 which, as shown, is securely received and retained by insulating member 20.

Connector member 22 is a metal member of essentially uniform cross-section which, in the embodiment shown, has an interlocking portion 54 that essentially corresponds in outer peripheral shape and size to the shape and size of C-shaped groove 50 of insulating member 20. Integrally formed with the interlocking portion 54 of connector member 22 is a stem portion 48 that extends forwardly and outwardly from insulating member 20 and has a screw groove 56 formed in its distal end for the purpose of securing thereto panel-retaining member 24.

As should be apparent, interlocking portion 54 of connector member 22 need not necessarily assume the precise shape shown and other interlocking shapes than that shown are considered to be within the contemplation of this invention. In addition, insulating member 20 need not necessarily assume the precise shape shown and, in fact, it is contemplated that insulating member 20 or insulating material of any shape could be molded onto or about or otherwise structurally associated with one end of connector member 22 so that metal connector member 22 can be supported on backing member 18 and spaced therefrom by insulating material.

Panel-retaining member 24 is essentially an elongated clip member extending the full length of each of the horizontal and vertical framing members and having formed on opposite longitudinal edges thereof a structure, such as grooves 58, adapted to support insulating glazing strips 26. Intermediate said longitudinal edges there is provided on said retaining member 24 a longitudinally extending boss 60, which, in the installed position of retaining member 24, preferably engages with or is only separated a short distance from the surface or distal end of connector member 22 that has formed therein the opening to screw groove 56. Suitable apertures (not shown) are provided in panel-retaining member 24 and extend through boss 60 for the purpose of adjustably securing panel-retaining member 24 to connector member 22 and relative to panel-backing member 18 by means of screw fasteners 28 extending through said apertures and received in screw groove 56. Also formed at or near the longitudinal edges of panel-retaining member 24, but on the side opposite that which is adapted to carry insulating glazing strips 26, are longitudinally extending flanges or ribs 30 over which a metal cover or cap member 32 is snapped and securely locked into place. Cover or cap members 32 can be of almost any desired shape, finish, color and depth of section. In the embodiment shown, cover member 32 is a U-shaped channel member having a web that presents a flat outer surface parallel to the curtain wall panels and a pair of flanges that present flat side surfaces which are coplanar with the side surfaces of the horizontal and vertical stiffening members.

The preferred method of assembly of the curtain wall construction of this invention involves inserting the interlocking portion 54 of connector member 22 longitudinally into the companion groove 50 in insulating member 20;

inserting the foregoing assembly longitudinally into the C-shaped groove 44 in panel-backing member 18; erecting a plurality of panel-backing members into a grid or frame of horizontal and vertical members; afiixing insulating strips 26 to the panel-backing members; setting a panel in place against each thus-formed frame of insulating strips; affixing insulating strips 26 to panel-retaining member 24; joining or securing a panel-retaining member 24 to each panel-backing member 18 by means of screw fasteners 28 being threadably received in screw groove 56 of connector member 22; and snapping cover member 32 over flanges or ribs 30 to provide the completed assembly.

It will be appreciated that, among other novel features, the construction of this invention provides a metal-faced, insulated curtain wall system having adjustable panelretaining members to accommodate any build-up of tolerances in the panel-backing members, insulating members and connector members, and, accordingly, an insulated system that is not inherently or unduly hampered by tolerance considerations. Also, the curtain wall system of this invention permits wide versatility in the finish, color, shape and/ or appearance of depth of section of the panel-framing members by reason of employing cap or cover members that can be fabricated to provide practically any desired finished appearance.

We claim:

1. An insulated curtain wall construction comprising a panel having an edge disposed between a metal panelbacking member and a metal panel-retaining member, a metallic connector member bridging a space between said backing member and said retaining member and joining said backing member and retaining member in assembled relation, said metallic connector member having a first portion received and retained within a logitudinal mounting groove on said backing member, said first portion of said connector member being retained within said mounting groove in interlocking engagement with a block of insulating material that supports said first portion of said connector member in spaced relation to said backing member, means carried on said backing member and coacting with said block of insulating material to prevent extraction of said insulating material through the longitudinal opening into said mounting groove, said connector member having a second portion extending outwardly of said mounting groove and having formed on its distal end means for adjustably securing thereto said panel-retaining member, said panel-retaining member being adjustably secured to said second portion of said connector member and having means formed on opposite longitudinal edges thereof to support insulating glazing strips, and insulating glazing material disposed between said panel and said panel-backing member and between said panel and said panel-retaining member.

2. An insulated curtain wall construction according to claim 1, wherein said panel-retaining member has means formed thereon for supporting a cover member and a channel-shaped cover member is affixed to said cover member supporting means.

3. An insulated curtain wall construction according to claim 2, wherein said metal panel-backing member comprises an elongated structural member having a longitudinally extending channel-shaped stitiening portion that carries thereon a longitudinally extending panel-backing portion, and said panel-backing portion comprises a pair of flange members extending from said stiffening portion and defining therebetween said longitudinal mounting groove for receiving and retaining said block of insulating material and said first portion of said metallic connector member, said flanges having formed on the free ends thereof said means to prevent extraction of said block of insulating material through the longitudinal opening into said mounting groove.

4. An insulated curtain wall construction according to claim 3, wherein said means to prevent extraction of said block of insulating material comprises a pair of longitudinally extending, opposed flanges that restrict the longitudinal opening into said mounting groove.

5. An insulated curtain Wall construction according to claim 4, wherein said block of insulating material comprises an elongated elastomeric member that essentially corresponds in cross-sectional shape and size to the crosssectional shape and size of said mounting groove, and said elastomeric member has a longitudinal groove formed therein that interlocks with said first portion of said connector member and essentially corresponds in cross-sectional shape and size to the cross-sectional shape and size of said first portion of said connector member.

References Cited UNITED STATES PATENTS 960,677 6/1910 McGann 52463 1,832,847 11/1931 Lane 52403 2,985,263 5/1961 Maciunas 52730 X 3,052,330 9/1962 Hammitt et a1. 52464 X 3,093,217 6/1963 Doede 52495 X 3,099,337 7/1963 Hetman 52-400 3,309,122 3/1967 Van Der Sluys et al. 52395 X 3,336,707 8/1967 Horgan 52395 X FOREIGN PATENTS 632,393 1/1962 Italy.

69,594 7/ 1915 Switzerland.

ALFRED C. PERHAM, Primary Examiner US. Cl. X.R. 

